When PLC meets ChatGPT: 10 traditional jobs that are about to disappear in industrial automation

——Will your job be replaced under the AI revolution?

1. Introduction: AI is devouring the “iron rice bowl” of industrial automation

In 2025, the “natural language programming PLC tool” jointly launched by Siemens and Microsoft has served more than 100,000 production lines worldwide. Engineers only need to say to AI: “When the conveyor belt detects red parts, start the robot arm to grab and classify”, and ChatGPT can automatically generate a complete ladder diagram code-this scenario completely subverts the traditional industrial control field.

Data shows: After adopting AI programming, the PLC development cycle of a certain automobile factory was shortened by 67%, and the debugging labor cost was reduced by 53%. When AI begins to understand the Modbus TCP protocol, optimize STL instructions, and even predict equipment failures, which positions will be the first to bear the brunt?

2. 10 traditional positions that are about to disappear

1. PLC manual programming engineer

Current situation: Need to be proficient in languages such as Ladder Diagram and FBD, and write thousands of lines of code
AI impact: ChatGPT generates code through natural language, supports mainstream PLCs such as Siemens S7-200 Smart, and has an error rate of less than 0.3%
Case: A food factory laid off 30% of its programming team and switched to AI generation + manual verification mode

2. On-site debugging technician

Pain point: Need to bring a computer to the site to troubleshoot communication faults line by line
AI replacement: TwinCAT Chat tool can remotely simulate the operating environment and locate Modbus TCP packet loss problems in 3 minutes

3. Equipment maintenance engineer

Traditional mode: Rely on experience to judge motor overheating or sensor failure
AI upgrade: Combining edge computing and historical data, ChatGPT predicts bearing life with an accuracy rate of 92%

4. Document Writer

Reason for replacement: AI automatically generates annotated code manuals, supporting multiple language versions

5. Basic Fault Diagnostician

Technology Change: ChatGPT analyzes S7-200 Smart logs and provides feedback on fault tree (FTA) in seconds

6. PLC Training Instructor

Education Revolution: Newbies can master FBD programming 4 times faster through interactive learning with ChatGPT

7. Hardware Configuration Specialist

Automation Trend: AI automatically recommends PLC models based on IO points, increasing selection efficiency by 80%

8. Quality Control Inspector

Visual Replacement: AI Visual Model + PLC Linkage, Real-time Detection of Part Defects (Missed Detection Rate <0.01%)

9. Data Collector

Technology Iteration: Python scripts are connected via Modbus TCP automatically captures PLC data, and the manual intervention rate is zero

10. Standardized tester

Efficiency crushing: AI simulates 200 abnormal working conditions to test PLC programs, and the time is compressed from 2 weeks to 4 hours

III. Survivor Law: 3 core skills of future engineers

1. AI collaboration ability

Master the precise description skills of “natural language to PLC code” (such as semantic specifications in Siemens cooperation projects)
Case: Excellent engineers manually optimize key safety logic after generating code frameworks through ChatGPT

2. Cross-domain integration

Integrate Python data analysis (such as predictive maintenance), machine vision (such as defect recognition) and PLC control

3. Ethics and safety thinking

Beware of the “black box risk” of AI code: a chemical plant caused a leakage accident due to failure to verify the emergency stop logic generated by AI

IV. Conclusion: Subversion or evolution?

When a German PLC manufacturer began to require applicants to submit “AI collaborative project experience”, this change was irreversible. But history has proven that every technological revolution will always create more new opportunities while destroying old jobs – for example, emerging professions such as “industrial AI trainer” and “PLC safety auditor” are on the rise.

Thinking question: If your job will be replaced by AI, will you choose to be “the person who controls AI” or “the person who is controlled by AI”?